Methods and apparatus for cooling syngas in a gasifier

ABSTRACT

A method of cooling hot fluid flowing through a chamber is provided. The method includes channeling cooling fluid through at least one cooling tube that extends through a passage of the chamber, and circulating the hot fluid flowing within the passage around the at least one cooling tube using at least one fluid diverter.

BACKGROUND OF THE INVENTION

This invention relates generally to integrated gasification combined-cycle (IGCC) power generation systems, and more specifically to a gasifier that includes an integral radiant syngas cooler.

At least some known IGCC systems include a gasification system that is integrated with at least one power-producing turbine system. For example, known gasifiers convert a mixture of fuel, air or oxygen, steam, and/or limestone into an output of partially combusted gas, sometimes referred to as “syngas”. The hot combustion gases are supplied to the combustor of a gas turbine engine, which powers a generator that supplies electrical power to a power grid. Exhaust from at least some known gas turbine engines is supplied to a heat recovery steam generator that generates steam for driving a steam turbine. Power generated by the steam turbine also drives an electrical generator that provides electrical power to the power grid.

At least some know gasification systems use a separate gasifier, and a physically-large radiant cooler to gasify bottoms, recover heat, and to remove solids from the syngas, to make the syngas useable by other systems. Such additional components and ancillary equipment needed to support operation of the gasifier and the radiant cooler add to the complexity, the capital expense, and operational manpower of the system.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a method of cooling hot fluid flowing through a chamber is provided. The method includes channeling cooling fluid through at least one cooling tube that extends through a passage of the chamber, and circulating the hot fluid flowing within the passage around the at least one cooling tube using at least one fluid diverter.

In another embodiment, a radiant cooler is provided. The radiant cooler includes at least one cooling tube extending through a passage of a chamber, and at least one fluid diverter coupled to the cooling tube for circulating a hot fluid flowing through the passage around the cooling tube.

In yet another embodiment, a gasifier is provided. The gasifier includes a passage extending therethrough, and a radiant cooler that includes at least one cooling tube extending through the passage, and at least one fluid diverter coupled to the cooling tube for circulating a reactant fluid flowing through the passage around the cooling tube.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an exemplary known integrated gasification combined-cycle (IGCC) power generation system;

FIG. 2 is a schematic view of an exemplary gasifier that includes an integral radiant syngas cooler and that may be used with the system shown in FIG. 1; and

FIG. 3 is an enlarged front view of a portion of the integral radiant syngas cooler shown in FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic diagram of an exemplary known integrated gasification combined-cycle (IGCC) power generation system 50. IGCC system 50 generally includes a main air compressor 52, an air separation unit 54 coupled in flow communication to compressor 52, a gasifier 56 coupled in flow communication to air separation unit 54, a gas turbine engine 10, coupled in flow communication to gasifier 56, and a steam turbine 58.

In operation, compressor 52 compresses ambient air that is channeled to air separation unit 54. In some embodiments, in addition to compressor 52 or alternatively, compressed air from gas turbine engine compressor 12 is supplied to air separation unit 54. Air separation unit 54 uses the compressed air to generate oxygen for use by gasifier 56. More specifically, air separation unit 54 separates the compressed air into separate flows of oxygen (O₂) and a gas by-product, sometimes referred to as a “process gas”. The process gas generated by air separation unit 54 includes nitrogen and will be referred to herein as “nitrogen process gas” (NPG). The NPG may also include other gases such as, but not limited to, oxygen and/or argon. For example, in some embodiments, the NPG includes between about 95% and about 100% nitrogen. The O₂ flow is channeled to gasifier 56 for use in generating partially combusted gases, referred to herein as “syngas” for use by gas turbine engine 10 as fuel, as described below in more detail. In some known IGCC systems 50, at least some of the NPG flow is vented to the atmosphere from air separation unit 54. Moreover, in some known IGCC systems 50, some of the NPG flow is injected into a combustion zone (not shown) within gas turbine engine combustor 14 to facilitate controlling emissions of engine 10, and more specifically to facilitate reducing the combustion temperature and reducing nitrous oxide emissions from engine 10. In the exemplary embodiment, IGCC system 50 includes a compressor 60 for compressing the nitrogen process gas flow before being injected into the combustion zone.

Gasifier 56 converts a mixture of fuel, O₂ supplied by air separation unit 54, steam, and/or limestone into an output of syngas for use by gas turbine engine 10 as fuel. Although gasifier 56 may use any fuel, in some known IGCC systems 50, gasifier 56 uses coal, petroleum coke, residual oil, oil emulsions, tar sands, and/or other similar fuels. In some known IGCC systems 50, the syngas generated by gasifier 56 includes carbon dioxide. In the exemplary embodiment, syngas generated by gasifier 52 is cleaned in a clean-up device 62 before being channeled to gas turbine engine combustor 14 for combustion thereof. Carbon dioxide (CO₂) may be separated from the syngas during clean-up and, in some known IGCC systems 50, may be vented to the atmosphere. Gas turbine engine 10 drives a generator 64 that supplies electrical power to a power grid (not shown). Exhaust gases from gas turbine engine 10 are channeled to a heat recovery steam generator 66 that generates steam for driving steam turbine 58. Power generated by steam turbine 58 drives an electrical generator 68 that provides electrical power to the power grid.

In some known IGCC systems 50, steam from heat recovery steam generator 66 is supplied to gasifier 56 for generating syngas.

Furthermore, in the exemplary embodiment, system 50 includes a pump 70 that supplies steam 72 from steam generator 66 to a radiant syngas cooler (not shown) within gasifier 56 to facilitate cooling the syngas flowing within gasifier 56. Steam 72 is channeled through the radiant syngas cooler wherein water 72 is converted to steam 74. Steam 74 is then returned to steam generator 66 for use within gasifier 56 or steam turbine 58.

FIG. 2 is a schematic view of an exemplary advanced solids removal gasifier 200 that includes an integral radiant syngas cooler 300. Gasifier 200 may be used with an IGCC, such as system 50 (shown in FIG. 1). In the exemplary embodiment, gasifier 200 includes an upper shell 202, a lower shell 204, and a substantially cylindrical vessel body 206 extending therebetween. A feed injector 208 penetrates upper shell 202 to enable a flow of fuel to be channeled into gasifier 200. More specifically, the fuel flowing through injector 208 is routed through one or more passages defined in feed injector 208 and is discharged through a nozzle 210 in a predetermined pattern 212 into a combustion zone 214 defined in gasifier 200. The fuel may be mixed with other substances prior to entering nozzle 210, and/or may be mixed with other substances when discharged from nozzle 210. For example, the fuel may be mixed with fines recovered from a process of system 50 prior to entering nozzle 210 and/or the fuel may be mixed with an oxidant, such as air or oxygen, at nozzle 210 or downstream from nozzle 210.

In the exemplary embodiment, combustion zone 214 is defined as a vertically-oriented, generally cylindrical space, that is substantially co-aligned with nozzle 210 in a serial flow communication. An outer periphery of combustion zone 210 is defined by a refractory wall 216 that includes a structural substrate, such as an Incoloy pipe 218 and a refractory coating 220 that substantially resists the effects of high temperatures and high pressures contained within combustion zone 210. In the exemplary embodiment, an outlet end 222 of refractory wall 216 includes a convergent outlet nozzle 224 that facilitates maintaining a predetermined backpressure in combustion zone 214, while permitting products of combustion and syngas generated in combustion zone 214 to exit combustion zone 214. The products of combustion may include gaseous byproducts, slag formed generally on refractory coating 220, and/or fine particular matter carried in suspension with the gaseous byproducts.

After exiting combustion zone 214, flowable slag and solid slag are gravity-fed into a lockhopper 226 coupled to bottom shell 204. Lockhopper 226 is maintained with a level of water that quenches the flowable slag into a brittle solid material that may be broken into smaller pieces when removed from gasifier 200. In the exemplary embodiment, lockhopper 226 captures approximately ninety percent of fine particulate exiting combustion zone 214.

In the exemplary embodiment, an annular passage 228 at least partially surrounds combustion zone 214. Passage 228 is partially defined by refractory wall 216 at an inner periphery, and by a cylindrical shell 230 that is substantially coaxially aligned with combustion zone 214 at a radially outer periphery of first passage 228. First passage 228 is sealed at the top by an upper flange 232. The gaseous byproducts and any remaining fine particulate are channeled from a downward direction 234 in combustion zone 214 to an upward direction 236 in passage 228. The rapid redirection at outlet nozzle 224 facilitates separating fine particulate and slag separation from gaseous byproducts.

The gaseous byproducts and any remaining fine particulate are channeled upward through passage 228 to an outlet 238. As the gaseous byproducts are channeled through passage 228, heat may be recovered from the gaseous byproducts and the fine particulate. For example, in one embodiment, the gaseous byproducts enter passage 228 at a temperature of approximately 2500° Fahrenheit and exit passage 228 at a temperature of approximately 1800° Fahrenheit. The gaseous byproducts and fine particulates are discharged from passage 228 through outlet 238 and are channeled into a second annular passage 240 wherein the gaseous byproducts and fine particulates are redirected to a downward flow direction 241. As gaseous byproducts and fine particulates flow through passage 240, heat may be recovered using for example, superheat tubes 242 that transfer heat from the flow of gaseous byproducts and the fine particulates to steam flowing through superheat tubes 242. For example, in one embodiment, the gaseous byproducts enter passage 240 at a temperature of approximately 1800° Fahrenheit and exit passage 240 at a temperature of approximately 1500° Fahrenheit.

When the flow of gaseous byproducts and the fine particulates reach a bottom end 244 of passage 240, passage 240 converges toward lockhopper 226. More specifically, at bottom end 244, the flow of gaseous byproducts and the fine particulates is channeled upward through a water spray 246 that desuperheats the flow of gaseous byproducts and the fine particulates. Heat removed from the flow of gaseous byproducts and the fine particulates tends to vaporize water spray 246 and agglomerate the fine particulates such that the fine particulates form a relatively larger ash clod that falls into lower shell 204. The flow of gaseous byproducts and the remaining fine particulates are channeled in a reverse direction towards a perforated plate 248 that circumscribes bottom end 244. A level of water is maintained above perforated plate 248 to facilitate removing additional fine particulate from the flow of gaseous byproducts. As the flow of gaseous byproducts and the remaining fine particulates percolate through perforated plate 248, fine particulates contained in the flow are entrapped in the water and carried through the perforations into a sump formed in bottom shell 204. A gap 250 defined between lockhopper 226 and bottom shell 204 enables the fine particulates to flow into lockhopper 226 wherein the fine particulates are facilitated to be removed from gasifier 200.

An entrainment separator 254 encircles an upper end of lower shell 204. More specifically, separator 254 is above perforated plate 248 and above the level of water covering perforated plate 248. Entrainment separator 254 may be for example, a cyclonic or centrifugal separator that includes a tangential inlet or turning vanes that impart a swirling motion to the gaseous byproducts and the remaining fine particulates flowing therethrough. The particulates are thrown outward by centrifugal force to the walls of separator 254 wherein the fine particulates coalesce and are gravity-fed to the separator bottom shell 204. Additionally, any remaining fine particulates impact a mesh pad, agglomerate with other particulates and are flushed to bottom shell 204.

Alternatively, entrainment separator 254 can be of a blade type, such as a chevron separator or an impingement separator. In a chevron separator, the gaseous byproducts pass between blades and are forced to travel in a tortuous or zigzag pattern. The entrained particulates and any liquid droplets cannot follow the gas streamlines, and impinge against the blade surfaces prior to coalescing, wherein the particulates are gravity-fed into bottom shell 204. Features such as hooks and pockets, can be added to the sides of the blades to facilitate improving particulate and liquid droplet capture. In addition, chevron grids can be stacked to provide a series of separation stages. Similarly, impingement separators create a cyclonic motion as gaseous byproducts and fine particulates pass over curved blades. A spinning motion is imparted that causes the entrained particulates and any liquid droplets to be forced against to the vessel walls, wherein the entrained particulates and any liquid droplets may be collected in bottom shell 204.

The flow of gaseous byproducts and any remaining fine particulates enter separator 254 wherein substantially all of any remaining entrained particulate and/or liquid droplets are removed form the flow of gaseous byproducts. The flow of gaseous byproducts exits gasifier 200 through an outlet 256 for further processing.

In the exemplary embodiment, gasifier 200 also includes a radiant syngas cooler 300 that is coupled within passage 228. In the exemplary embodiment, cooler 300 includes an inlet 302, an outlet 304, and a plurality of cooling tubes 306 that extend therebetween. Cooling tube 306 is positioned within passage 228 to facilitate cooling syngas flowing through passage 228. Moreover, in the exemplary embodiment, cooler 300 is a three-pass cooler that includes three cooling tubes 306. In an alternative embodiment, cooler 300 may include any suitable number of cooling tubes 306 that facilitate cooling the syngas in passage 228. Moreover, in one embodiment, cooler 300 includes a plurality of cooling tubes 306 spaced circumferentially about a centerline C_(L) of cylindrical vessel 206.

In the exemplary embodiment, inlet 302 extends from a first end 308 of cooling tube 306 to an exterior 310 of cylindrical vessel 206. Similarly, outlet 304 extends from a second end 312 of cooling tube 306 to exterior 310. In the exemplary embodiment, inlet 302 is positioned below outlet 304. In an alternative embodiment, inlet 302 is positioned above outlet 304 or substantially planar therewith.

During operation, pump 70 channels steam 72 from steam generator 66 through inlet 302 and into cooling tube first end 308. Alternatively, steam 72 may be channeled to inlet 302 from any suitable source. Steam 72 is then channeled through cooling tube 306 towards second end 312. Simultaneously, syngas channeled through passage 228 flows around cooling tube 306 to facilitate a heat exchange between the syngas and steam 72. Specifically, because steam 72 has a temperature that is less than the temperature of the syngas, steam 72 absorbs heat from the syngas to facilitate cooling the syngas.

Furthermore, in addition to cooling the syngas, cooling tube 306 facilitates cooling of refractory wall 216. More specifically, as steam 72 absorbs heat from the syngas, a higher temperature steam 74 is produced in cooling tube 306 and is discharged through outlet 304. In the exemplary embodiment, steam 74 is discharged from outlet 304 to steam generator 66 for further use within system 50. In an alternative embodiment, steam 74 is channeled to any suitable portion of system 50 and/or any other system that requires steam. In another alternative embodiment, steam 74 is discharged from system 50 to the atmosphere.

FIG. 3 is an enlarged front view of a portion of radiant syngas cooler 300. Specifically, FIG. 3 is a front view of cooling tube 306. In the exemplary embodiment, cooling tube 306 extends between inlet 302 and outlet 304, and includes a fluid diverter 350 that extends circumferentially around cooling portion 306. Specifically, in the exemplary embodiment, fluid diverter 350 extends helically around cooling tube 306 from cooling tube first end 308 to cooling tube second end 312. Although the exemplary embodiment illustrates only one fluid diverter 350, in an alternative embodiment, cooling tube 306 includes any suitable number of fluid diverters 350.

During operation, in the exemplary embodiment, steam 72 is channeled through cooling tube 306 to facilitate cooling syngas flowing through passage 228 of gasifier 200. In an alternative embodiment, any suitable cooling fluid is channeled through cooling tube 306. Simultaneously, syngas flowing through passage 228 is directed by fluid diverter 350 to facilitate circulating the reactant fluid around cooling tube 306. As the reactant fluid is circulated around cooling tube 306, contact between cooling tube 306 and the reactant fluid is increased to facilitate heat transfer between steam 72 and the syngas.

In one embodiment, a method of cooling hot fluid flowing through a chamber is provided. The method includes channeling cooling fluid through at least one cooling tube that extends through a passage of the chamber, and circulating the hot fluid flowing within the passage around the at least one cooling tube using at least one fluid diverter. In one embodiment, the method also includes channeling the hot fluid around the at least one cooling tube in a pattern that facilitates increasing heat transfer between the at least one cooling tube and the hot fluid. Further, in one embodiment, the method also includes channeling cooling fluids through at least one cooling tube to facilitate transferring heat from the hot fluid to the cooling fluid. Moreover, in one embodiment, the method includes circulating the hot fluid with at least one fluid diverter extending circumferentially around the cooling tube. In addition, in one embodiment, the method includes circulating the hot fluid with at least one fluid diverter extending helically around the cooling tube. Further, in one embodiment, the method also includes channeling steam through at least one cooling tube. Moreover, in one embodiment, the method includes channeling cooling fluid through at least one cooling tube to facilitate cooling a wall of the chamber.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

The above-described methods and systems facilitate circulating syngas around cooling tubes within a gasifier. Specifically, the fluid diverter circulates the syngas such that contact between the syngas and the cooling tube is increased. As such, cooling of syngas in an integrated gasification is facilitated to be improved without increasing the number of components within the IGCC. As a result, costs associated with the operation and maintenance of the IGCC are facilitated to be reduced, while the efficiency of the IGCC is enhanced.

Exemplary embodiments of gasification systems and methods of cooling syngas in a gasifier are described above in detail. The gasification system components illustrated are not limited to the specific embodiments described herein, but rather, components of the system may be utilized independently and separately from other components described herein. For example, the gasification system components described above may also be used in combination with different IGCC system components.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. 

1. A method of cooling fluid flowing through a chamber, said method comprising: channeling a hot fluid downwardly from a combustion zone to a first passage surrounding the combustion zone, wherein the combustion zone is defined within a refractory wall, and the first passage is defined between the refractory wall and an outer wall spaced radially outwardly from the refractory wall; channeling the hot fluid upwardly through the first passage to a second passage surrounding the first passage; channeling cooling fluid through a plurality of cooling tubes positioned within the first passage, wherein the cooling fluid is channeled into an inlet extending through an outer wall of the chamber, through a plurality of cooling tubes coupled to the inlet, and through an outlet extending through the chamber outer wall, each cooling tube of the plurality of cooling tubes including a first end coupled to the inlet, a second end coupled to the outlet, and an outer surface that extends between the first end and the second end, wherein each cooling tube extends through the first passage such that the plurality of cooling tubes are spaced circumferentially about the combustion zone; circulating the hot fluid flowing within the first passage around each cooling tube using at least one fluid diverter coupled to each cooling tube such that the hot fluid is channeled from the combustion zone across each cooling tube outer surface from the first end towards the second end; and channeling the cooling hot fluid downwardly through the second passage towards an outlet.
 2. A method in accordance with claim 1 wherein circulating the fluid within the passage around each cooling tube comprises channeling the fluid around each cooling tube in a pattern that facilitates increasing heat transfer between each cooling tube and the fluid.
 3. A method in accordance with claim 1 wherein channeling cooling fluid through each cooling tube comprises channeling cooling fluids through each cooling tube to facilitate transferring heat from the fluid to the cooling fluid.
 4. A method in accordance with claim 1 wherein circulating the fluid using at least one fluid diverter comprises circulating the fluid with at least one fluid diverter extending circumferentially around at least one cooling tube of the plurality of cooling tubes.
 5. A method in accordance with claim 1 wherein circulating the fluid using at least one fluid diverter comprises circulating the fluid with at least one fluid diverter extending helically around at least one cooling tube of the plurality of cooling tubes.
 6. A method in accordance with claim 1 wherein channeling cooling fluid through the plurality of cooling tubes comprises channeling steam through each cooling tube.
 7. A method in accordance with claim 1 wherein channeling cooling fluid through the plurality of cooling tubes comprises channeling cooling fluid through each cooling tube to facilitate cooling a wall of the chamber.
 8. A radiant cooler for use with a gasifier, said radiant cooler comprising: an inlet extending through an outer wall of a chamber of the gasifier; an outlet extending through the outer wall; and a plurality of cooling tubes extending between said inlet and said outlet, each cooling tube of said plurality of cooling tubes comprising a first end coupled to said inlet, a second end coupled to said outlet, and an outer surface that extends between said first end and said second end, each said cooling tube extending through a first passage defined between the outer wall and a refractory wall positioned within the chamber, wherein the refractory wall defines a combustion zone that is at least partially surrounded by the first passage such that said plurality of cooling tubes are spaced circumferentially about said combustion zone and wherein an interior wall divides the chamber between the outer wall and the refractory wall into two passages such that the first passage including the cooling tubes extends between the refractory wall and the interior wall, and the second passage is formed between the interior wall and the outer wall, the first passage is oriented for channeling a hot fluid from the combustion zone and upwardly through the first passage, each said cooling tube is oriented within the first passage such that the hot fluid is channeled substantially parallel with respect to each cooling tube and across each said cooling tube outer surface from said first end towards said second end, said inlet oriented to channel cooling fluid into each said cooling tube, each said cooling tube comprising at least one fluid diverter coupled to an outer surface of said cooling tube for circulating the hot fluid flowing through the first passage around each said cooling tube outer surface from said first end towards said second end, and wherein said second passage is oriented for channeling the reactant fluid from said first passage downwardly through said second passage.
 9. A radiant cooler in accordance with claim 8 wherein said at least one fluid diverter is configured to facilitate increasing heat transfer between said at least one cooling tube and the hot fluid.
 10. A radiant cooler in accordance with claim 8 wherein said radiant cooler is configured to facilitate transferring heat from the hot fluid to a cooling fluid flowing through said radiant cooler.
 11. A radiant cooler in accordance with claim 8 wherein said at least one fluid diverter extends circumferentially around said cooling tube.
 12. A radiant cooler in accordance with claim 8 wherein said at least one fluid diverter extends helically around said cooling tube.
 13. A radiant cooler in accordance with claim 8 wherein said radiant cooler is configured to facilitate transferring heat from the hot fluid to steam flowing through said radiant cooler.
 14. A radiant cooler in accordance with claim 8 wherein said radiant cooler facilitates cooling a wall of the chamber.
 15. A gasifier comprising: a chamber defined by at least an outer wall; a refractory wall positioned within said chamber, said refractory wall comprising an inner surface that defines a combustion zone therein; an interior wall positioned between said outer wall and said refractory wall such that a first passage is defined between said interior wall and said refractory wall and a second passage is defined between said interior wall and said outer wall, wherein said first passage is oriented for channeling a flow of reactant fluid from said combustion zone upwardly through said first passage, said second passage is oriented for channeling the reactant fluid from said first passage downwardly through said second passage; and a radiant cooler comprising: an inlet extending through said outer wall; an outlet extending through said outer wall; and a plurality of cooling tubes extending between said inlet and said outlet, each cooling tube of said plurality of cooling tubes comprising a first end coupled to said inlet, a second end coupled to said outlet, and an outer surface that extends between said first end and said second end, each said cooling tube extending through said first passage such that the plurality of cooling tubes are spaced circumferentially about the combustion zone and such that the reactant fluid is channeled upwardly from said combustion zone and across each said cooling tube outer surface from said first end towards said second end, each said cooling tube configured to channel a flow of cooling fluid from said inlet to said outlet, each said cooling tube comprising at least one fluid diverter coupled to said cooling tube for circulating the reactant fluid flowing through the passage around said cooling tube outer surface from said first end towards said second end.
 16. A gasifier in accordance with claim 15 wherein said at least one fluid diverter is configured to facilitate increasing heat transfer between said cooling tube and the reactant fluid.
 17. A gasifier in accordance with claim 15 wherein said radiant cooler is configured to facilitate transferring heat from the reactant fluid to a cooling fluid flowing through said radiant cooler.
 18. A gasifier in accordance with claim 15 wherein said at least one fluid diverter extends circumferentially around said cooling tube.
 19. A gasifier in accordance with claim 15 wherein said at least one fluid diverter extends helically around said cooling tube.
 20. A gasifier in accordance with claim 15 wherein said radiant cooler is configured to facilitate transferring heat from the reactant fluid to steam flowing through said radiant cooler. 